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Procedia Engineering 100 (2015) 1253 – 1261

25th DAAAM International Symposium on Intelligent Manufacturing and Automation, DAAAM

2014

The Influence of High-Speed Milling Strategies on 3D Surface

Roughness Parameters
Andris Loginsa, Toms Torimsa
a
Riga Technical University, Faculty of Transport and Mechanical Engineering,
Ezermalas St. 6K-105, Riga, LV-1006

Abstract

Nowadays in die-cast manufacturing high speed milling are used to increase quality, accuracy and speed of material processing,
also to reduce processing costs and save machining time. This paper is devoted for research of high-speed processing regimes
impacts and their effect on the surface roughness quality of the machined material and 3D surface parameter values. This paper
contains recommendations for die-cast manufacturers, deploying HSM, to improve machining process and obtain required
surface quality. Analysis of variance methodology is used in this research. Research identify the most appropriate HSM regimes,
that most important is chosen material type or material mechanical properties, influencing kurtosis of the scale-limited surface
(Sku) and height of the bearing area ratio curve (Stp). Feed rate is most significant for texture aspect ratio (Str) and strategy type
– influencing parameter of arithmetic mean surface height (Sa) and valley fluid retention index (Svi).
© 2015
© 2015The The Authors.
Authors. Published
Published by Elsevier
by Elsevier Ltd.
Ltd. This is an open access article under the CC BY-NC-ND license
Peer-review under responsibility of DAAAM International Vienna.
(http://creativecommons.org/licenses/by-nc-nd/4.0/).
Peer-review under responsibility of DAAAM International Vienna
Keywords:Die-mould manufacturing; high-speed milling; 3D surface roughness; ANOVA; analysis of variance

1. Introduction

The machining methods currently used worldwide for die-cast manufacturing are only optional, or do not offer
optimal efficiency, to achieve the highest standards in manufactured die moulds. To reach such standards, engineers
must think about new manufacturing techniques, to increase quality and save machining time.
________________
* Corresponding author. Tel.: +371 262 68 246
E-mail address: logins.andris@gmail.com

1877-7058 © 2015 The Authors. Published by Elsevier Ltd. This is an open access article under the CC BY-NC-ND license
(http://creativecommons.org/licenses/by-nc-nd/4.0/).
Peer-review under responsibility of DAAAM International Vienna
doi:10.1016/j.proeng.2015.01.491
1254 Andris Logins and Toms Torims / Procedia Engineering 100 (2015) 1253 – 1261

HSM or high-speed milling technology is relatively new. In order to better define this methodology, it is
necessary to use parameters that characterize the surface quality and roughness. However, publicly available
scientific publications are not providing in-depth studies on the correlation between HSM and surface
topography.[2] These parameters are identified by means of 3D surface roughness measurements, in accordance
with the standard ISO 25178:2012 - Geometrical product specifications (GPS) -- Surface texture: Areal -- Part 2:
Terms, definitions and surface texture parameters. This methodology is also the new standard for surface texture
measurements.
The machining methods currently used worldwide for die-cast manufacturing are only optional, or do not offer
optimal efficiency, to achieve the highest standards in manufactured die moulds. To reach such standards, engineers
must think about new manufacturing techniques, to increase quality and save machining time. HSM or high-speed
milling technology is relatively new. In order to better define this methodology, it is necessary to use parameters that
characterize the surface quality and roughness. However, publicly available scientific publications are not providing
in-depth studies on the correlation between HSM and surface topography.[2] These parameters are identified by
means of 3D surface roughness measurements, in accordance with the standard ISO 25178:2012 - Geometrical
product specifications (GPS) -- Surface texture: Areal -- Part 2: Terms, definitions and surface texture parameters.
This methodology is also the new standard for surface texture measurements.
Our research was begun in Riga Technical University, in cooperation with the Polytechnic University of
Valencia, Spain. During this research we needed to explore the surface roughness quality obtained by processing
with high-speed milling, using different combinations of cutting regimes. The first part of this research was started
in Valencia, where all the subsamples were machined using different combinations of regimes and milling
trajectories. For the present purposes, trajectory means tool movement over the material surface.
The aim of this research is to identify what kind of conventional machining methods are currently used for die-
mould manufacturing, and if they can be replaced by high-speed machining, as well as the impact of the machining
regimes on 3D surface roughness parameters. To achieve this, the following tasks had to be carried out:

a) Comparison of conventional die mould manufacturing techniques and high-speed milling techniques.
b) Take measurements of the 3D surface texture and roughness for the two most frequently used die mould
manufacturing steels.
c) Identification of the most characteristic 3D surface texture and roughness parameters after HSM.
d) Mathematical identification of the most critical technological parameters influencing each specific 3D surface
roughness parameter.
e) Development of practical recommendations for die mould manufacturers, to apply these technological
parameters in the manufacturing process and optimize surface roughness, save machining time and decrease
labour costs.

2. High-speed machining: a review

High-speed machining (HSM) has gained importance over the past few years, following technological
developments that have enabled its implementation. As a result of advances in machine tools and cutting tool
technology, HSM has become a cost-effective manufacturing process for producing parts with high precision and
surface quality. Until recently, high-speed machining was applied in machining aluminium alloys for manufacturing
complicated parts used in the aircraft industry. This technology was successfully applied with significant
improvements in machine tools, spindles and controllers [3, 4]. Recently, with the advance of cutting tool
technologies, HSM has also been employed for machining alloy steels for making dies/moulds used in the
production of a wide range of automotive components, as well as plastic moulding parts [5]. High-speed machining
can be defined as machining at considerably higher cutting speeds and feed rates compared to those in traditional
methods. HSM processes enable high material removal rates, low cutting forces, reduced lead times and improved
part precision [6]. The distinction between conventional and high-speed machining is based on the workpiece
material being machined, type of cutting operation, and the cutting tool used [7]. The high rotation speeds and feed
rates of HSM impose new constraints on the tool path: a sharp corner requires the tool to slow down, change its
direction and accelerate again until the desired maximum speed is reached again. Also, when cutting hard material,
 Andris Logins and Toms Torims / Procedia Engineering 100 (2015) 1253 – 1261 1255

rapid changes in tool load may result in increased tool wear. Since sharp corners or, more generally, points of high
curvature of the tool path often also result in a rapid change in the tool load, it is obvious that they should be avoided
for HSM tool paths. [11]
Many advantages of HSM have been cited. The most common advantages reported are high metal removal rates,
low cutting forces, minimal workpiece distortion, the ability to machine thin-walled sections, use of simple fixtures,
little or no damage to workpiece surface integrity, reduction in cutting tool variety, burr-free components, and easier
chip disposal [3], [7]. Figure 4 shows some characteristics of the high-speed machining process [8]. Figure 1. also
shows that by increasing cutting speeds, the cutting forces can be reduced and better surfaces can be obtained,
instead of reduced cutting tool life.

Fig. 1. Characteristics of the high-speed machining process [5].

For the practical aspect of our research, we used a Gentiger GT-66V-T16B high-speed milling machine, with a
spindle speed of up to 16,000 min-1, spindle power of up to 26 kW, a rapid feed rate of 30 m/min and maximum
working feed rate of 20 m/min. The machine is equipped with a Siemens 840D NC controller and BT-40 cone-type
spindle.

3. 3D Surface roughness measurements

The existing standards for surface roughness cover two-dimensional surface roughness parameters (ISO
4287:1984), and also three-dimensional (3D) surface texture, as in real life. The 3D surface roughness parameters in
particular are important for solving mechanical contact surface problems related to the accuracy of 3D surface
roughness characteristics. [9] In this case, it is necessary to extend this research to surface roughness measurements
that give more comprehensive information on surface roughness and texture. To analyse surface texture in this
research, the ISO 25178:2012 - Geometrical product specifications - standard was chosen. Measuring the 3D surface
roughness requires collecting a precise number of points (in this case, profiles or lines parallel to the main axes of
the sample). The surface displacement occurs in two orthogonal directions: x and y (Fig. 2). In the x-direction, the
data are collected with Nx being the number of datapoints, whereas in the y-direction there are Ny lines (profiles)
[10].
1256 Andris Logins and Toms Torims / Procedia Engineering 100 (2015) 1253 – 1261

Fig. 2. 3D measurement scheme of surface displacement [7].

The measurements for all machined samples were taken using the Taylor Hobson Form Talysurf Intra 50
measuring device and TalyMap Expert data software was used for the data processing.

4. Approach and research objectives

This research began in the Department of Mechanical and Materials Engineering at the Polytechnic University of
Valencia and incorporates work at the Material Processing Technology Department of Riga Technical University.
The experiment was based on processing 3 different types of high-strength material with HSM technology, using
different combinations of cutting parameters. Two types of processed steels that are widely used in die mould
manufacturing 1.2312 (40CrMnMo58-6) (Fig. 3.) and 1.1730 (C45W) were selected. For comparison, a third high-
strength material, unalloyed titanium BT1-0 Grade 2, was also chosen.

Fig. 3. Material 1.2312 sample with subsamples.

A variable combination of cutting parameters was chosen for each machined sample. Certain parameters were
kept constant, such as cutting depth (0.3mm for all samples) and spindle speed (15,707rpm for mould steels and
3,666rpm for titanium). Other chosen parameter values were variable. One of the most potentially significant factors
is feed rate. Feed rates were chosen in accordance with manufacturers’ recommendations. For mould materials,
 Andris Logins and Toms Torims / Procedia Engineering 100 (2015) 1253 – 1261 1257

where spindle speeds are higher, the cutting speeds also are higher. The following feed speeds were chosen for
mould steels:

- 2,513mm/min (0.08mm/tooth);
- 6,283mm/min (0.2mm/tooth);
- 12,566mm/min (0.4mm/tooth).

Another of the selected variable technological parameters was tool overlap. Overlap characterizes tool
displacement compared with the previous movement trajectory over the material surface. Two different values were
chosen: 0.05mm and 0.1mm.
For the cutting strategy, three different cutting strategies were chosen, to approximate experiment to real
manufacturing process:

- Linear strategy type or linear path (LP) – linear tool movement over the surface;
- Circular strategy type or circular path (CP) – circular tool movement by Archimedes spiral;
- Two linear strategies or two linear paths (TLP) – the combination of linear tool movement along both the X
and Y axes.

Both types of milling modes were used – up (cutter rotation coincides with feed direction) and down (cutter
rotation is opposite to the feed direction) milling modes. In this research, we need to analyze the impact of all the
aforementioned parameters on the 3D surface texture parameters (Fig.4.)

Fig. 4. Input parameter influence on 3D surface texture parameters.

Each machined sample is divided into 16 subsamples, processed by different combinations of technological
parameters. When all subsamples were machined, the surface texture measurements (3D roughness measurements)
were taken. Also photographs were taken to compare with pictures from the roughness measuring device Talymap
Expert software.
1258 Andris Logins and Toms Torims / Procedia Engineering 100 (2015) 1253 – 1261

0 0.5 1 1.5 mm μm
0
16
0.2
14
0.4
12

0.6
10

0.8 8

1 6

1.2 4

1.4 2

0
mm

Fig. 5.a) Sample no. 6. (LP 0.05, Feed 0.4mm-1) microscope camera image b) Surface texture of sample. 6. (LP 0.05, Feed 0.4mm-1) by Talymap
Expert.

5. Analysis

After all the measurements were taken, the data was divided into the appropriate groups and the most significant
3D roughness parameters for high-speed milling were chosen. This was done by preparing the correlation matrix in
the Rcommander software, where a set of 3D roughness parameters are inserted into the matrix of n random
variables, to obtain the most significant parameters for each group.
The chosen 3D roughness parameters were collated in charts, to prepare graphs that illustrate changes in
roughness parameters resulting from feed level, overlap and strategy type. In order to describe the influence of one
input parameter on surface roughness parameters, multifactorial analysis is required, which characterizes the impact
of several input parameters on specific surface roughness parameters.
For the ANOVA multifactorial analysis using Rcommander software, all technological parameters have to be
replaced with factors. ANOVA – analysis of variance is then conducted on pairs of these factors, using each chosen
surface parameters as a response function, to see how each specific factor influences one or another surface texture
parameter.
The trend line coefficients of the polynomial regression equation with argument x for material 1.1730 (sample
no.6. with linear pattern) shows that the feed rate is the major influence (Fig.6). This is approved also by ANOVA
multifactorial analysis, done by Rcommander software and SPSS Statistics.

y = -31.818x2 + 14.568x - 0.4076 (1)

However, for the sample with circular pattern milling, the equation ratios confirm that differences between feed
levels is lower (Fig.7):

y = -13.84x2 + 6.29x - 0.01 (2)

In a sample machined with an overlap of 0.1mm, the roughness parameter Sa increases together with feed level.
The equation ratios prove this correlation:

y = -8.14x2 + 6.27x - 0.13 (3)

In those graphs, it shown, that behavior of regression trend-line is similar in both of cases for parameter Sa. The
situation is not so definitely clear for other texture parameters. For example, parameters Sku and Stp are strongly
influenced by chosen material type. Texture parameters in average is 1,2 times lower for material with higher
 Andris Logins and Toms Torims / Procedia Engineering 100 (2015) 1253 – 1261 1259

mechanical properties, and lower elongation. Feed rate impact than is only secondary, influencing parameter Stp
only at low overlap rates. Therefor parameter Str - Texture aspect ratio of the surface, is mostly affected by feed
level. Ratio shows, that after feed level changes, the balance of processing is missed and forces, probably, should be
different in cutting process.
When this analysis is carried out for each of the three selected materials, it becomes clear that the technological
parameters of feed rate, strategy and milling mode are more pronounced – there is a non-linear correlation between
surface roughness parameters and the technological parameters. Therefore, a technological parameter such as
overlap can be excluded from further analysis.

Fig. 6. Sa Parameter’s dependence on feed level with linear Fig. 7. Sa Parameter’s dependence on feed level with circular
strategy for material type 1.1730. strategy for material type 1.1730.

After analysis, we identified which technological parameter affects each particular surface roughness parameter.
These are given in Table. 1. To mention appropriate values of texture parameters for each of technological regimes,
this research should be continued, based on those conclusions provided by this paper. In comparison with other
researches, this paper provides actual data about influence significance of chosen technological regimes.

Table 1. Technological parameters and Surface texture parameters influenced by them.

3D texture parameter Influenced by ANOVA signif. ratio
Sa Strategy 0.002253
Sku Material 0.01678
Stp Material 0.03999
Str Feed rate 0.01621
Svi Strategy 0.04633

Conclusions

By using modern surface machining methods in tool manufacturing industry, like in die mold manufacturing, is
just as much as need to use modern surface characterization methods, such of 3D surface roughness measurements.
If there are clearly defined technological parameters and obtained surface roughness parameters, of conventional
tool manufacturing, than there is need to define surface texture parameter dependence of used technological
regimes. The following results have been introduction of this research. Results are based on mathematically proven
hypotheses, to show the dependence of surface texture parameters on technological parameters.
1260 Andris Logins and Toms Torims / Procedia Engineering 100 (2015) 1253 – 1261

Analysis of available literature indicates that HSM technology can fully replace conventional machining
methods, such as milling, grinding, electromechanical and electro-erosion methods. Analyses show that HSM
technology is being used increasingly nowadays, to save machining time and reduce manufacturing costs.

1. Based on the correlation matrix, the five most characteristic surface texture parameters for HSM were
chosen. They are Sa – the arithmetical mean height of the surface, Sku – the kurtosis of the scale limited
surface, STp – the height of the bearing area ratio curve, Str – the texture aspect ratio and Svi – the valley
fluid retention index.
2. ANOVA multifactorial analysis was conducted for the five most characteristic surface texture parameters, in
which the most significant influences were identified as machining strategy and material type.
3. Data analysis identifies that the circular machining strategy generally gives better results: 1.5 to 2 times
lower average surface roughness than the linear machining strategy.
4. Our research indicates that the most significant influence is the material’s mechanical properties. This is
supported by the use of various technological parameters, which resulted in different surface roughness
parameter values and their distribution, and proven by ANOVA analysis.
5. The material’s mechanical properties have the greatest influence on surface roughness parameters. These are
identified in the parameters Sku and Stp. The Stp parameter is affected by changes in the material’s
mechanical properties. When cutting forces are altered, increased vibrations result from surface defects that
occur in the form of surface roughness peaks, which are distributed irregularly over the surface. These peaks
can be up to 5 times higher than the rest of the measured surface. The most significant result was seen in
samples where the parameter St > 8μm.

Evaluating the overall factor influence on surface texture parameters and based on the conclusions above, some
practical recommendations can be made for applying technological parameters in the manufacturing process when
using HSM technology.

1. In the case of one type of material, the greatest influence is the type of manufacturing strategy:
a) It is recommended to use a circular path, as proved by roughness parameters and surface micro-
topography image, where the surface has the lowest roughness and the most even structure.
b) Conversely it is recommended to use a linear path where the overall surface roughness parameters are
lower than with the circular path.
c) It is advisable to avoid using Two Linear paths. In the second passage, the material is not in fact being
cut. In this case, the surface texture peaks are smoothed by the cutting edge.
2. It is important to observe the material’s mechanical properties.
a) Material 1.1730 is more reliable for die mould manufacturing when using HSM technology, compared
with the other materials used in this research.
b) For unalloyed titanium machining, we recommend not using the same technological parameters as for
die mould material machining, otherwise surface roughness will be significantly increased.
3. The third most significant technological factor is feed rate.
a) We would recommend using a low or exceptionally a medium feed rate, when it is necessary to speed
up production.
b) The average feed rate is recommended for machining unalloyed titanium.
In the next stage, it’s to increase amount of machined samples, to make measurements of already machined sample
with different mechanical properties (Sample Nr.4.). Authors predict that this will increase the probability of getting
more precisely correlation between cutting technological parameters and surface roughness parameters, including
surface micro-hardness.
 Andris Logins and Toms Torims / Procedia Engineering 100 (2015) 1253 – 1261 1261

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